Integrated vent gas separator and flare stack

ABSTRACT

According to one aspect, an apparatus includes a separator vessel adapted to separate solid and liquid materials from gas materials; a flame arrestor in fluid communication with the separator vessel and through which the gas materials are adapted to flow; and a flare stack adapted to burn off the gas materials. The flare stack includes a vent pipe and an igniter. In another aspect, a system at a wellsite includes one or more separators adapted to be in fluid communication with a wellbore; one or more vent gas lines in fluid communication with the one or more separators; and an integrated vent gas separator and flare stack. In an exemplary embodiment, the one or more separators comprise at least one of a mud-gas separator and a shale-gas separator. In yet another aspect, a kit has first and second configurations. In still yet another aspect, a method is provided.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of the filing date of, and priorityto, U.S. patent application No. 61/887,141, filed Oct. 4, 2013, theentire disclosure of which is hereby incorporated herein by reference.

TECHNICAL FIELD

This disclosure relates in general to vent gas separators and flarestacks and, in particular, an integrated vent gas separator and flarestack.

BACKGROUND OF THE DISCLOSURE

During the drilling of an oil or gas well, different materials may bedischarged from the well. The discharged materials may include mixturesof solid, liquid and gas materials. These materials may be processeddownstream of the well. As a result of one or more of these downstreamprocesses, a multiphase flow including solid, liquid and gas materialsmay be generated. At least some of the materials in the multiphase flowmay be separated from the remainder of the materials, and/or some of thematerials may be burned. In some cases, some of the separated materialsmay not be properly contained, and/or possible fire hazards may begenerated in connection with the separation and/or burning processes.Therefore, what is needed is an apparatus or method that addresses oneor more of these issues, among others.

SUMMARY

In a first aspect, there is provided an apparatus that includes aseparator vessel adapted to separate solid and liquid materials from gasmaterials; a flame arrestor in fluid communication with the separatorvessel and through which the gas materials are adapted to flow; and aflare stack adapted to burn off the gas materials. The flare stack ispositioned so that the flame arrestor is vertically positioned betweenthe separator vessel and the flare stack. The flare stack includes avent pipe in fluid communication with the flame arrestor and positionedso that the flame arrestor is vertically positioned between theseparator vessel and vent pipe; and an igniter in fluid communicationwith the vent pipe. The igniter is positioned so that the vent pipe isvertically positioned between the flame arrestor and the igniter.

In an exemplary embodiment, the apparatus includes a skid on which theseparator vessel, the flame arrestor, and the flare stack are mounted.The flame arrestor is positioned so that the separator vessel isvertically positioned between the skid and the flame arrestor.

In another exemplary embodiment, the apparatus includes one or moreguide wires extending from the skid to the flare stack to secure andstabilize the igniter.

In yet another exemplary embodiment, the apparatus includes an outletpipe generally centered on the top of the separator vessel and extendingupward therefrom. The flame arrestor is in fluid communication with theoutlet pipe and is positioned so that the outlet pipe is verticallypositioned between the separator vessel and the flame arrestor. Theseparator vessel is generally centered on the skid.

In certain exemplary embodiments, the apparatus includes one or moreguide wires to secure and stabilize the igniter, each of the one or moreguide wires extending to the flare stack from the skid. The centering ofthe outlet pipe on the top of the separator vessel, and the centering ofthe separator vessel on the skid, facilitates the securement andstabilization of the igniter by the one or more guide wires.

In an exemplary embodiment, the separator vessel defines an internalregion and includes an access port and a cap flange removably connectedthereto. The access port provides access to the internal region. Whenthe solid and liquid materials are separated from the gas materials, thecap flange is connected to the access port and the separator vessel is aclosed vessel that is closed to the atmosphere.

In another exemplary embodiment, the separator defines an internalregion in which the solid and liquid materials are adapted to beseparated from the gas materials. The apparatus further includes aninlet pipe via which the solid, liquid, and gas materials are adapted toflow into the internal region. The inlet pipe includes a firstconnection that extends angularly towards the separator vessel and isconnected thereto. The angular extension of the first connection definesan angle from a horizontal plane. The angle from the horizontal planeranges from greater than 0 degrees to less than 90 degrees.

In yet another exemplary embodiment, at least respective portions of thesolid, liquid, and gas materials are adapted to flow into the internalregion, via the first connection, in a generally angular direction thatcorresponds to the first angle. The first angle ranges from about 10degrees to about 80 degrees.

In certain exemplary embodiments, the separator defines an internalregion in which the solid and liquid materials are adapted to beseparated from the gas materials. The apparatus further includes aninlet pipe via which the solid, liquid, and gas materials are adapted toflow into the internal region. The inlet pipe includes ahorizontally-extending portion that extends axially along the separatorvessel, the horizontally-extending portion including first and secondconnections located at opposing ends, respectively, of thehorizontally-extending portion. The first and second connections areconnected to the separator vessel. The solid, liquid, and gas materialsare adapted to flow into the internal region via the first and secondconnections.

In an exemplary embodiment, each of the first and second connectionsextends angularly towards the separator vessel. Each of the angularextensions of the first and second connections defines an angle from ahorizontal plane. The angle from the horizontal plane ranges fromgreater than 0 degrees to less than 90 degrees.

In a second aspect, there is provided a system at a wellsite. The systemincludes one or more separators adapted to be in fluid communicationwith a wellbore at the wellsite; one or more vent gas lines in fluidcommunication with the one or more separators; and an integrated ventgas separator and flare stack, including a skid; a vessel mounted on theskid, in fluid communication with the one or more vent gas lines, andadapted to separate solid and liquid materials from gas materials; aflame arrestor in fluid communication with the vessel and positioned sothat the vessel is vertically positioned between the skid and the flamearrestor; and a flare stack in fluid communication with the flamearrestor and adapted to burn off the gas materials. The flare stack ispositioned so that the flame arrestor is vertically positioned betweenthe vessel and the flare stack.

In an exemplary embodiment, the flare stack includes a vent pipe and anigniter connected thereto.

In another exemplary embodiment, the system includes one or more guidewires extending from the skid to the flare stack. The one or more guidewires secure and stabilize the igniter.

In yet another exemplary embodiment, the vessel defines an internalregion and includes an access port and a cap flange removably connectedthereto. The access port provides access to the internal region. Whenthe solid and liquid materials are separated from the gas materials, thecap flange is connected to the access port and the vessel is a closedvessel that is closed to the atmosphere.

In certain exemplary embodiments, the one or more separators include atleast one of a mud-gas separator and a shale-gas separator.

In a third aspect, there is provided a kit which, when assembled, isadapted to process a multiphase flow at a wellsite, the multiphase flowincluding solid, liquid, and gas materials. The kit includes a skid; avessel mounted on the skid and into which the multiphase flow is adaptedto flow to separate the solid and liquid materials from the gasmaterials, wherein the mounting of the vessel on the skid definesopposing first and second side portions of the skid, and wherein thevessel is positioned between the opposing first and second side portionsof the skid; an inlet pipe connected to the vessel and via which themultiphase is adapted to flow into the vessel, wherein at least aportion of the inlet pipe extends above the first side portion; a flamearrestor; a vent pipe; and an igniter. The kit has a first configurationin which: each of the flame arrestor, the vent pipe, and the ignitereither is mounted on the second side portion of the skid or extends overthe second side portion of the skid; and each of the vent pipe and theigniter extends horizontally. The kit has a second configuration inwhich: the flame arrestor extends vertically and is positioned so thatthe vessel is vertically positioned between the skid and the flamearrestor; the gas materials are adapted to flow through the flamearrestor; the vent pipe extends vertically and is positioned so that theflame arrestor is vertically positioned between the vessel and the ventpipe; the gas materials are adapted to flow through the vent pipe; theigniter extends vertically and is positioned so that the vent pipe isvertically positioned between the flame arrestor and the igniter; andthe igniter is adapted to burn off the gas materials.

In an exemplary embodiment, when the kit is in the first configuration:one of the vent pipe and the igniter is mounted on the second sideportion of the skid; the other of the vent pipe and the igniter extendsabove the second side portion of the skid; and the flame arrestor ismounted on the second side portion of the skid.

In another exemplary embodiment, the vessel defines an internal regionand includes an access port and a cap flange removably connectedthereto. The access port provides access to the internal region. Whenthe solid and liquid materials are separated from the gas materials, thecap flange is connected to the access port and the vessel is a closedvessel that is closed to the atmosphere.

In a fourth aspect, there is provided a method that includes providing askid and a separator vessel mounted on the skid, wherein the mounting ofthe separator vessel on the skid defines opposing first and second sideportions of the skid, wherein the separator vessel is positioned betweenthe opposing first and second side portions of the skid, and whereineach of a flame arrestor, a horizontally-extending vent pipe, and ahorizontally-extending igniter either is mounted on the second sideportion of the skid or extends over the second side portion of the skid;accessing the flame arrestor at the second side portion of the skid;connecting the flame arrestor to the separator vessel so that the flamearrestor extends vertically; accessing the horizontally-extending ventpipe at the second side portion of the skid; connecting the vent pipe tothe flame arrestor so that the vent pipe extends vertically; accessingthe horizontally-extending igniter at the second side portion of theskid; and connecting the igniter to the vent pipe so that the igniterextends vertically.

In an exemplary embodiment, the method includes connecting one or moreguide wires between the igniter and the skid to secure and stabilize theigniter.

In another exemplary embodiment, an inlet pipe is connected to theseparator vessel and at least a portion of the inlet pipe extends overthe first side portion of the skid. The method further includesconnecting one or more fluid lines to the inlet pipe; conveying amultiphase flow into the separator vessel via the one or more fluidlines and the inlet pipe, the multiphase flow including solid, liquid,and gas materials; separating, using the separator vessel, the solid andliquid materials from the gas materials; conveying the gas materialsupwardly into the flame arrestor; and conveying the gas materialsupwardly from the flame arrestor and into the igniter.

In yet another exemplary embodiment, the one or more fluid lines includeat least one vent gas line that is in fluid communication with one of amud-gas separator and a shale-gas separator.

In certain exemplary embodiments, the separator vessel defines aninternal region and includes an access port and a cap flange removablyconnected thereto. The access port provides access to the internalregion.

Other aspects, features, and advantages will become apparent from thefollowing detailed description when taken in conjunction with theaccompanying drawings, which are a part of this disclosure and whichillustrate, by way of example, principles of the inventions disclosed.

DESCRIPTION OF FIGURES

The accompanying drawings facilitate an understanding of the variousembodiments.

FIG. 1 is a perspective view of an apparatus according to an exemplaryembodiment.

FIG. 2 is a front elevational view of the apparatus of FIG. 1, accordingto an exemplary embodiment.

FIG. 3 is a left side elevational view of the apparatus of FIGS. 1 and2, according to an exemplary embodiment.

FIG. 4 is a top plan view of the apparatus of FIGS. 1-3, according to anexemplary embodiment.

FIG. 5 is a diagrammatic illustration of the apparatus of FIGS. 1-4installed at an oil and gas wellsite, according to an exemplaryembodiment.

FIGS. 6 and 7 are flow chart illustrations of a method of processingmultiphase flow at the oil and gas wellsite of FIG. 5, according to anexemplary embodiment.

FIG. 8 is a diagrammatic illustration of a system installed at an oiland gas wellsite according to an exemplary embodiment, the systemincluding an apparatus.

FIG. 9 is a perspective view of the apparatus of FIG. 8, according to anexemplary embodiment.

FIGS. 10-12 are respective elevational views of the apparatus of FIG. 9,according to an exemplary embodiment.

FIG. 13 is a sectional view of a portion of the apparatus of FIGS. 9-12taken along line 13-13 of FIG. 9, according to an exemplary embodiment.

FIG. 14 is a sectional view of a portion of the apparatus of FIGS. 9-13taken along line 14-14 of FIG. 13, according to an exemplary embodiment.

FIG. 15 is a view similar to that of FIG. 9, but also depicting guidewires according to an exemplary embodiment.

FIG. 16 is a view similar to that of FIG. 9, but depicting the apparatusin a different configuration according to an exemplary embodiment.

FIGS. 17 and 18 are elevational views of the apparatus in theconfiguration of FIG. 16, according to an exemplary embodiment.

FIG. 19 is a flow chart illustration of a method of installing theapparatus of FIGS. 8-18, according to an exemplary embodiment.

DETAILED DESCRIPTION

In an exemplary embodiment, as illustrated in FIGS. 1-4, an apparatus isgenerally referred to by the reference numeral 10 and includes a skid 12on which a secondary containment vessel 14 is mounted. A separatorvessel 16 is connected to the secondary containment vessel 14. A flamearrestor 18 is connected to the separator vessel 16. A flare stack 20 isconnected to the flame arrestor 18, and includes an integrated igniter22 at the upper end portion thereof. A frame 24 is mounted on the skid12, and is connected to the secondary containment vessel 14. The frame24 includes a horizontally-extending working platform 26. Guide wires 28a, 28 b, 28 c, and 28 d extend to the upper end portion of the flarestack 20 from respective ones of four corners defined by the skid 12. Inan exemplary embodiment, one or more of the guide wires 28 a, 28 b, 28 cand 28 d are connected to the upper end portion of the flare stack 20.In an exemplary embodiment, one or both of the guide wires 28 a and 28 bare connected to the igniter 22, and the guide wires 28 c and 28 d areconnected to the upper end portion of the flare stack 20. In anexemplary embodiment, the guide wires 28 a, 28 b, 28 c and 28 d are allconnected to the upper end portion of the flare stack 20.

The frame 24 includes vertical supports 30 a, 30 b, 30 c and 30 dextending upward from the skid 12. The working platform 26 is connectedto the respective upper ends of the vertical supports 30 a, 30 b, 30 cand 30 d.

The secondary containment vessel 14 is in the form of a box-likestructure and includes a vertically-extending side portion 32 aextending between the vertical supports 30 a and 30 b, avertically-extending side portion 32 b extending between the verticalsupports 30 b and 30 c, a vertically-extending side portion 32 cextending between the vertical supports 30 c and 30 d, and avertically-extending side portion 32 d extending between the verticalsupports 30 d and 30 a. A horizontally-extending top portion 34 isconnected to the respective upper ends of the side portions 32 a, 32 b,32 c and 32 d. The top portion 34 of the secondary containment vessel 14is positioned beneath, and is spaced in a parallel relation from, theworking platform 26.

The secondary containment vessel 14 defines an interior, which isdefined by at least the top portion 34 and the side portions 32 a, 32 b,32 c and 32 d, as well as by either the skid 12 or a bottom portionconnected to or otherwise mounted on the skid 12; in an exemplaryembodiment, the secondary containment vessel 14 includes one or moreinternal liners disposed within the internal region. In an exemplaryembodiment, the secondary containment vessel 14 is a stand-alone tankconnected to the skid 12 and/or one or more of the vertical supports 30a, 30 b, 30 c and 30 d. In several exemplary embodiments, instead of, orin addition to being in the form of a box-like structure, the secondarycontainment vessel 14 is in the form of a cylindrical structure, abarrel-like structure, a duct-like structure, a closed-pan structure, aclosed-tray structure, or any combination thereof

In an exemplary embodiment, the frame 24 is part of the secondarycontainment vessel 14. In an exemplary embodiment, the frame 24 and thesecondary containment vessel 14 are separate structures, each of whichis connected to the other and/or to the skid 12. In an exemplaryembodiment, the secondary containment vessel 14 is a structure separatefrom the frame 24, and includes the top portion 34 and the side portions32 a, 32 b, 32 c and 32 d.

A drain port 36 is formed through the side portion 32 a at the lower endportion thereof. A plug or cap 38 is removably connected to the drainport 36. A liquid-level switch 40 is connected to the side portion 32 aat the upper end portion thereof. The liquid-level switch 40 is adaptedto sense the fluid level within the secondary containment vessel 14,under conditions to be described below. In an exemplary embodiment, theliquid-level switch 40 is a Rosemount® 2100 Series Vibrating Fork LiquidLevel Switch, which is available from Emerson Process ManagementRosemount Inc., Chanhassen, Minn.

The side portion 32 a includes an access port 42 and a cap flange 44removably connected thereto. In an exemplary embodiment, the access port42 and/or the cap flange 44 may be characterized as a manway or acleanout, which provides access to the secondary containment vessel 14.Likewise, the side portion 32 c includes an access port 46 and a capflange 48 removably connected thereto. In an exemplary embodiment, theaccess port 46 and/or the cap flange 48 may be characterized as a manwayor a cleanout, which provides access to the interior of the secondarycontainment vessel 14. In an exemplary embodiment, as shown FIGS. 1-4,the access port 46 opposes the access port 42.

The separator vessel 16 includes a cylindrical body 50 connected to thetop portion 34 of the secondary containment vessel 14 via a flange 52,which is fastened to the top portion 34. The secondary containmentvessel 14 is vertically positioned between the skid 12 and the separatorvessel 16. An internal region 54 is at least partially defined by thecylindrical body 50. Although not shown in the figures, an opening isformed through the top portion 34 so that the internal region 54 of theseparator vessel 16 is in fluid communication with the interior of thesecondary containment vessel 14; the flange 52 extends circumferentiallyaround the opening formed through the top portion 34. Due at least inpart to the top portion 34 and the connection of the separator vessel 16thereto via the flange 52, the secondary containment vessel 14 is aclosed-top tank. No part of the secondary containment vessel 14 isdirectly open to the atmosphere, that is, the secondary containmentvessel 14 is closed to the atmosphere, when the separator vessel 16 isconnected to the secondary containment vessel 14, the drain port 36 isplugged with the cap 38, and the access ports 42 and 46 are closed bythe cap flanges 44 and 48, respectively.

An inlet 56 is connected to the cylindrical body 50, and defines aninlet fluid passage 56 a in fluid communication with the internal region54. In an exemplary embodiment, and as shown in FIGS. 1-4, the inlet 56is a tangential inlet. The separator vessel 16 further includes a flange58 connected to the cylindrical body 50 opposite the flange 52. A cap 60is connected to the upper portion of the cylindrical body 50 via aflange 62, which is connected to the flange 58. In an exemplaryembodiment, the internal region 54 is partially defined by the cap 60.

In an exemplary embodiment, the separator vessel 16 is a cyclonicseparator. In an exemplary embodiment, the separator vessel 16 is avortex separator. In an exemplary embodiment, the separator vessel 16includes a vortex finder extending within the internal region 54; in anexemplary embodiment, the vortex finder includes a vertically-extendingtubular member. In an exemplary embodiment, the separator vessel 16includes one or more wear plates (not shown) disposed in the internalregion 54 and proximate the inlet fluid passage 56 a; the one or morewear plates are adapted to protect internal surfaces defined by theseparator vessel 16 from fluid flow into the separator vessel 16 via theinlet 56. In an exemplary embodiment, the separator vessel 16 includesone or more baffles (not shown) disposed within the internal region 54and vertically below the inlet 56; the one or more baffles are adaptedto remove entrained gas from multiphase flow. In an exemplaryembodiment, the separator vessel 16 includes one or more condenserbaffles (not shown) disposed within the internal region 54 and proximatethe flange 58 and/or the cap 60; the one or more condenser baffles areadapted to prevent any upward liquid flow out of the separator vessel16.

In several exemplary embodiments, the separator vessel 16 and thesecondary containment vessel 14 may be formed as a single vessel. Inseveral exemplary embodiments, a single vessel may be substituted forthe combination of the separator vessel 16 and the secondary containmentvessel 14.

The flame arrestor 18 is connected to the top of the cap 60 of theseparator vessel 16. The separator vessel 16 is vertically positionedbetween the secondary containment vessel 14 and the flame arrestor 18.The flame arrestor 18 is in fluid communication with the separatorvessel 16. In an exemplary embodiment, the flame arrestor 18 is anEnardo® Series 8 High Pressure Deflagration Flame Arrestor, which isavailable from Enardo, LLC, Tulsa, Okla.

The flare stack 20 is connected to the flame arrestor 18 opposite thecap 60, and extends upward from the flame arrestor 18. The flamearrestor 18 is vertically positioned between the flame arrestor 18 andthe flare stack 20. The flare stack 20 is in fluid communication withthe flame arrestor 18. The working platform 26 of the frame 24 isgenerally coplanar with the connection between flare stack 20 and theflame arrestor 18. In an exemplary embodiment, an opening is formedthrough the working platform 26, and one or both of the flame arrestor18 and the flare stack 20 extend within the opening. In an exemplaryembodiment, the frame 24 includes integrated handrails and a ladder; inseveral exemplary embodiments, the integrated handrails may be connectedto the working platform 26 to provide safety for personnel standing onthe working platform 26, and the ladder may provide safe access to theworking platform 26.

In an exemplary embodiment, as illustrated in FIG. 5 with continuingreference to FIGS. 1-4, the apparatus 10 is installed at an oil and gaswellsite 64, the wellsite 64 including a wellbore 66 that extends withina subterranean formation (not shown) and may be used in oil and gasexploration and production operations. To install the apparatus 10, theskid 12 is placed on a horizontal surface, such as the ground, at thewellsite 64. In an exemplary embodiment, the apparatus 10 may betransported to, and installed at, the wellsite 64 in the assembledcondition shown in FIGS. 1-4. One or more fluid lines 68 such as, forexample, one or more pipes or piping systems, are connected to the inlet56 so that the apparatus 10 is in fluid communication with the wellbore66 at the wellsite 64. In several exemplary embodiments, the apparatus10 is in fluid communication with the wellbore 66 via at least one ormore separators 70, that is, the apparatus 10 is in fluid communicationwith the one or more separators 70, which, in turn, are in fluidcommunication with the wellbore 66. In several exemplary embodiments,the one or more separators 70 include one or more mud-gas separators,one or more shale-gas separators, or any combination thereof. In anexemplary embodiment, the one or more fluid lines 68 are gas vent lines,and thus the apparatus 10 is in fluid communication with the one or moreseparators 70 via the one or more gas vent lines.

In operation, in an exemplary embodiment, with continuing reference toFIGS. 1-5, a multiphase flow travels from the one or more separators 70,through the one or more fluid lines 68, and into the internal region 54of the separator vessel 16 via the inlet fluid passage 56 a of the inlet56. The multiphase flow traveling through the one or more fluid lines 68includes solid, liquid and gas materials. The separator vessel 16operates to separate the solid and liquid materials from the gasmaterials in the multiphase flow, conveying the gas materials upwardsthrough the flame arrestor 18 and into the flare stack 20. The remainingsolid and liquid materials (which have been separated from the gasmaterials) fall out of the separator vessel 16 and into the secondarycontainment vessel 14.

In several exemplary embodiments, during operation, the inlet 56 of theseparator vessel 16 is a tangential inlet (as shown in FIGS. 1-4) andthe multiphase flow exits the inlet fluid passage 56 a and flowsspirally within the internal region 54. During this spiral flow, atleast respective portions of the solid and liquid materials of themultiphase flow are slung against the inside surface of the cylindricalwall 50 and flow axially downwards towards the secondary containmentvessel 14. In contrast, the gas materials in the multiphase flow, whichare relatively lighter in weight, are not so slung and instead aregenerally disposed closer to the radial center of the internal region54. As a result, the solid and liquid materials are separated from thegas materials, and the gas materials flow axially upwards towards theflame arrestor 18. In several exemplary embodiments, the separatorvessel 16 operates as a vortex or cyclonic separator.

In several exemplary embodiments, to separate the solid and liquidmaterials from the gas materials in the multiphase flow, the separatorvessel 16 is sized and/or configured so that the lighter gas materialsare permitted to rise or flow upwards towards the flame arrestor 18, andso that the heavier solid and liquid materials fall or flow downwardstowards the secondary containment vessel 14. In several exemplaryembodiments, the separator vessel 16 and the secondary containmentvessel 14 are combined into a single vessel in which the separation andcontainment functions occur. In several exemplary embodiments, a singlevessel is substituted for the combination of the separator vessel 16 andthe secondary containment vessel 14, and the separation and containmentfunctions occur in the single vessel.

The gas materials separated by the separator vessel 16 rise or flowupwards through the flame arrestor 18 and subsequently into the flarestack 20. The flare stack 20, which includes the igniter 22, operates toburn off the gas materials flowing into the flare stack 20.

The flame arrestor 18 allows the gas materials to flow therethrough, butarrests or stops a flame from propagating therethrough in order toprevent a larger fire or explosion. In several exemplary embodiments,the flame arrestor 18 stops any flame from the flare stack 20 frompropagating through the flame arrestor 18 and into the separator vessel16. The flame arrestor 18 prevents post-separation flame flashback. Inseveral exemplary embodiments, the flame arrestor 18 includes one ormore thermocouples, which may be in communication with a controller tomonitor the temperature of the flame arrestor 18 during the operation ofthe apparatus 10; in some exemplary embodiments, the controller mayactivate an alarm and/or take other action(s) in response to thetemperature monitoring.

In several exemplary embodiments, the flare stack 20 and the igniter 22integrated therewith provide increased safety due to an increasedelevation of flare, and the flame arrestor 18 provides integrated flareflashback prevention.

In contrast to the gas materials, the solid and liquid materials fall orflow downwards into the secondary containment vessel 14 for collectiontherein. The solid and liquid materials continue to collect in thesecondary containment vessel 14 until they reach a predetermined level,at which point the liquid-level switch 40 detects that the secondarycontainment vessel 14 is full. In an exemplary embodiment, when thesecondary containment vessel 14 is full, the secondary containmentvessel 14 is drained by removing the cap 38 from the drain port 36,thereby allowing at least the liquid materials to flow out of thesecondary containment vessel 14.

During the operation of the apparatus 10, in an exemplary embodiment,the liquid-level switch 40 may continuously or nearly continuouslymonitor the liquid level within the secondary containment vessel 14. Inan exemplary embodiment, the liquid-level switch 40 may be incommunication with a controller to monitor the liquid level, and/ordetect when the liquid level reaches the predetermined level, within thesecondary containment tank 40; in some exemplary embodiments, thecontroller may activate an alarm and/or take other action(s) in responseto the liquid-level monitoring. Such other actions may includeautomatically draining the secondary containment vessel 14 byautomatically opening the drain port 36.

During the operation of the apparatus 10, in several exemplaryembodiments, the guide wires 28 a, 28 b, 28 c and 28 d secure andstabilize the igniter 22. In several exemplary embodiments, the guidewires 28 a, 28 b, 28 c and 28 d secure and stabilize the igniter 22during the transportation of the apparatus 10, and/or during theinstallation of the apparatus 10 at the wellsite 64.

As noted above, due at least in part to the top portion 34 and theconnection of the separator vessel 16 thereto via the flange 52, thesecondary containment vessel 14 is a closed-top tank. In severalexemplary embodiments, the respective interconnections between thevessel 14 and the separator vessel 16, between the separator vessel 16and the flame arrestor 18, and between the flame arrestor 18 and theflare stack 20, ensure that separation is achieved in a closed system,with post-separation dynamics ensuring that only vent gas is dischargedto the flare stack 20.

In several exemplary embodiments, the one or more fluid lines 68 is avent gas line, and the apparatus 10 functions both as a vent gasseparator (or vent gas scrubber) and a secondary containment flaresystem. The apparatus 10 effectively separates and contains solid andliquid carryover in the vent gas flowing through the fluid lines 68 andinto the apparatus 10, while burning off the gas materials. In severalexemplary embodiments, since the secondary containment vessel 14 isintegrated with the separator vessel 16, the apparatus 10 ensures thecollection and storage of solid and liquid materials entrained in thevent gas.

As noted above, due at least in part to the top portion 34 and theconnection of the separator vessel 16 thereto via the flange 52, thesecondary containment vessel 14 is a closed-top tank. The secondarycontainment vessel 14 being a closed-top tank, as well as theinterconnection between the secondary containment vessel 14 and theseparator vessel 16, the interconnection between the separator vessel 16and the flame arrestor 18, and the interconnection between the flamearrestor 18 and the flare stack 20, provide a closed system in whichonly the flare stack 20 is open to the atmosphere during the operationof the apparatus 10, that is, during the separation of the solid andliquid materials from the gas materials and the burning off of the gasmaterials, when the drain port 36 is plugged with the cap 38 and theaccess ports 42 and 46 are closed by the cap flanges 44 and 48,respectively.

In several exemplary embodiments, the apparatus 10 is an integratedseparator and secondary containment flare apparatus. In severalexemplary embodiments, the apparatus 10 is an integrated vent gasseparator (or vent gas scrubber) and secondary containment flareapparatus.

In several exemplary embodiments, the above-described integration andvertical stack-up of the different components of the apparatus 10reduces the footprint of the apparatus 10 and provides a compactstructure. Further, the above-described integration and verticalstack-up of the different components of the apparatus 10 facilitates thetransportation and installation of the apparatus 10. Still further, theabove-described integration and vertical stack-up of the differentcomponents of the apparatus 10 facilitates the above-described operationof the apparatus 10 in that, for example, the heavier solid and liquidmaterials fall from the separator vessel 16 and into the secondarycontainment vessel 14, and the lighter gas materials rise up from theseparator vessel 16, through the flame arrestor 18, and into the flarestack 20.

In several exemplary embodiments, the respective sizes of the apparatus10 and its components may be scaled accordingly. In an exemplaryembodiment, the length and width of the skid 12 may be about 192 inchesand 72 inches, respectively, the height of the flare stack 20 from thehorizontal surface on which the skid 12 rests may be about 225 inches,and the height of the working platform 26 from the horizontal surface onwhich the skid 12 rests may be about 104 inches.

In an exemplary embodiment, as illustrated in FIGS. 6 and 7 withcontinuing reference to FIGS. 1-5, a method of processing multiphaseflow at the wellsite 64 is generally referred to by the referencenumeral 72. The method 72 includes at step 72 a mounting the secondarycontainment vessel 14 on the skid 12, at step 72 b connecting theseparator vessel 16 to the secondary containment vessel 14, and at step72 c connecting the flame arrestor 18 to the separator vessel 16. Atstep 72 d, the skid 12, and thus also the secondary containment vessel14, the separator vessel 16, and the flame arrestor 18, are transportedto the wellsite 64. At step 72 e, the skid 12, and thus also thesecondary containment vessel 14, the separator vessel 16, and the flamearrestor 18, are installed at the wellsite 64. At step 72 f, the one ormore vent gas lines 68 are connected between the separator vessel 16 andthe one or more separators 70. At step 72 g, the multiphase flow isconveyed from the one or more separators 70 and into the one or morevent gas lines 68. At step 72 h, the multiphase flow is conveyed fromthe one or more vent gas lines 68 and into the separator vessel 16. Atstep 72 i, using the separator vessel 16, solid and liquid materials inthe multiphase flow are separated from gas materials in the multiphaseflow. At step 72 j, the solid and liquid materials are conveyeddownwardly into the secondary containment vessel 14. At step 72 k, thegas materials are conveyed upwardly into the flame arrestor 18. In anexemplary embodiment, the method 72 further includes connecting theflare stack 20 to the flame arrestor 18, and conveying the gas materialsupwardly from the flame arrestor 18 and into the flare stack 20. In anexemplary embodiment, the method 72 further includes connecting one ormore guide wires between the skid 12 and the upper end portion of theflare stack 20 to secure and stabilize the igniter 22.

In several exemplary embodiments, the majority of the flare stack 20 maynot be positioned on the skid 12; instead, at least a portion (such afluid line or piping) of the flare stack 20 may be connected to, andpositioned above, the flame arrestor 18, and at least the majority ofthe remaining portion of the flare stack 20 may be positioned next to,or at a distance away from, the skid 20.

In an exemplary embodiment, as illustrated in FIG. 8, a system isgenerally referred to by the reference numeral 74 and includes anapparatus 76, which is installed at an oil and gas wellsite 78. Thewellsite 78 includes a wellbore 80 that extends within a subterraneanformation (not shown) and may be used in oil and gas exploration andproduction operations. The system 74 further includes one or moreseparators 82, which are in fluid communication with the wellbore 80.The apparatus 76 includes a fluid inlet 84, which is in fluidcommunication with the one or more separators 82 via one or more fluidlines 86. The apparatus 76 is in fluid communication with the wellbore80 via the one or more fluid lines 86 and the one or more separators 82.In several exemplary embodiments, the one or more separators 82 includeone or more mud-gas separators, one or more shale-gas separators, or anycombination thereof. In an exemplary embodiment, the one or more fluidlines 86 are gas vent lines, and thus the apparatus 76 is in fluidcommunication with the one or more separators 82 via the one or more gasvent lines.

In an exemplary embodiment, as illustrated in FIGS. 9-12 with continuingreference to FIG. 8, the apparatus 76 includes a skid 88 on which aseparator vessel 90 is mounted via vessel mounting brackets 92 a, 92 b,and 92 c, which are connected to the skid 88. The vessel 90 includesopposing axial end portions 90 a and 90 b. An access port 90 c (shownmost clearly in FIG. 13) is formed in the vessel 90 at the axial endportion 90 b. A cap flange 90 d is removably connected to the accessport 90 c. In an exemplary embodiment, the access port 90 c and/or thecap flange 90 d may be characterized as a manway or a cleanout, whichprovides access to the interior of the vessel 90.

The skid 88 defines a length 88 a and a width 88 b perpendicularthereto. The mounting brackets 92 a, 92 b, and 92 c are horizontallyspaced from each other along a length direction of the skid 88. Thevessel 90 is generally cylindrical in shape, and extends horizontallyalong a length direction of the skid 88. The vessel 90 is generallycentered on the skid 88, with the center of the vessel 90 beinggenerally positioned about midway along the length 88 a of the skid 88,and about midway along the width 88 b of the skid 88. Opposing sideportions 88 c and 88 d of the skid 88 are defined by the position of thevessel 90 on the skid 88. The side portions 88 c and 88 d extend alongthe length 88 a of the skid 88. The vessel 90 is positioned between theopposing side portions 88 c and 88 d. Igniter mounting brackets 94 a and94 b are connected to the skid 88 on the side portion 88 c thereof, andare horizontally spaced along a length direction of the skid 88.Similarly, flame arrestor mounting brackets 96 a and 96 b are connectedto the skid 88 on the side portion 88 c thereof, and are horizontallyspaced along a length direction of the skid 88.

An outlet pipe 98 is connected to, and generally centered on, the top ofthe vessel 90, and extends vertically upward therefrom. Gussets 100extend between the vessel 90 and the outlet pipe 98, supporting theoutlet pipe 98. A concentric reducer 102 is connected to the outlet pipe98 and extends vertically upward therefrom. A flame arrestor 104 isconnected to the concentric reducer 102 and extends vertically upwardtherefrom so that the concentric reducer 102 is vertically positionedbetween the outlet pipe 98 and the flame arrestor 104. The flamearrestor 104 is in fluid communication with the outlet pipe 98 and ispositioned so that the outlet pipe 98 is vertically positioned betweenthe vessel 90 and the flame arrestor 104, and so that the vessel 90 isvertically positioned between the skid 88 and the flame arrestor 104. Inan exemplary embodiment, the flame arrestor 104 is an Enardo® Series 8High Pressure Deflagration Flame Arrestor, which is available fromEnardo, LLC, Tulsa, Okla. A vent pipe 106 is connected to, and in fluidcommunication with, the flame arrestor 104 and extends vertically upwardtherefrom so that the flame arrestor 104 is vertically positionedbetween the concentric reducer 102 and the vent pipe 106. An igniter 108is connected to, and in fluid communication with, the vent pipe 106 andextends vertically upward therefrom so that the vent pipe 106 isvertically positioned between the flame arrestor 104 and the igniter108. In several exemplary embodiments, the combination of at least thevent pipe 106 and the igniter 108 connected thereto constitutes a flarestack having an integrated igniter at the upper end portion thereof. Inseveral exemplary embodiments, the vent pipe 106 is omitted and a lowerend tubular portion of the igniter 108 is a vent pipe connected to, andin fluid communication with, the flame arrestor 104, and is verticallypositioned between the flame arrestor 104 and the igniter 108; inseveral exemplary embodiments, such an igniter 108 with its lower endtubular portion being a vent pipe constitutes a flare stack having anintegrated igniter at the upper end portion thereof. In an exemplaryembodiment, the vent pipe 106 and the igniter 108 may be combined andform an integral component, with the lower end tubular portion thereofbeing the vent pipe and the upper end portion being the igniter; inseveral exemplary embodiments, such a combination constitutes a flarestack having an integrated igniter at the upper end portion thereof.

A drain pipe 110 is connected to the vessel 90 and positioned verticallybetween the skid 88 and the vessel 90, extends axially along theunderside of the vessel 90. In several exemplary embodiments, the drainpipe 110 extends through, and/or is supported by, the vessel mountingbrackets 92 a, 92 b, and 92 c. A fluid outlet 110 a is defined by thedrain pipe 110 at a location proximate the axial end portion 90 a of thevessel 90. The drain pipe 110 includes a valve 110 b adapted to controlfluid flow out of the drain pipe 110 via the fluid outlet 110 a. Anigniter control box 112 is connected to the vessel 90 at the axial endportion 90 a thereof, and is adapted to control the operation of theigniter 108. Vent pipe mounting brackets 114 a and 114 b are connectedto the vessel 90. The vent pipe mounting brackets 114 a and 114 b extendfrom the side of the vessel 90 so that the vent pipe mounting brackets114 a and 114 b are positioned above the side portion 88 c of the skid88. A sensor pipe 116 extends from the side of the vessel 90 at a lowerportion thereof. The sensor pipe 116 extends from the side of the vessel90 so that the sensor pipe 116 is positioned over the side portion 88 cof the skid 88.

A liquid-level switch 118 is connected to the sensor pipe 116. At leasta portion of the liquid-level switch 118 is housed within the sensorpipe 116. The liquid-level switch 118 is adapted to sense the liquidlevel within the vessel 90, under conditions to be described below. Inan exemplary embodiment, the liquid-level switch 118 is a horizontallevel control switch with an annulus plug. In an exemplary embodiment,the liquid-level switch 118 is a Wellmark® Model 790 HorizontalFloatswitch, which is available from The Wellmark Company, L.L.C.,Oklahoma City, Okla.

An inlet pipe 120 is located above the side portion 88 d of the skid 88,and includes a horizontally-extending portion 120 a. The fluid inlet 84is defined by the horizontally-extending portion 120 a. As indicatedabove, the fluid inlet 84 is in fluid communication with the one or morefluid lines 86 shown in FIG. 8. The horizontally-extending portion 120 ais located and extends above the side portion 88 d of the skid 88, andextends along a portion of the vessel 90. A vertically-extending portion120 b is connected to the horizontally-extending portion 120 a via anelbow connection 120 c. A transversely-extending portion 120 d isconnected to the vertically-extending portion 120 b via an elbowconnection 120 e. The transversely-extending portion 120 d extendshorizontally over the top of the vessel 90 and along a width directionof the skid 88. A horizontally-extending portion 120 f is connected tothe transversely-extending portion 120 d. The horizontally-extendingportion 120 f extends axially along the vessel 90, and is closer to theside portion 88 c than to the side portion 88 d. Thehorizontally-extending portion 120 f includes an elbow connection 120 gat one end thereof, and an opposing elbow connection 120 h at the otherend thereof. The elbow connections 120 g and 120 h are connected to thevessel 90. The elbow connection 120 g is connected to the vessel 90 atthe axial end portion 90 a of the vessel 90. The elbow connection 120 his connected to the vessel 90 at the axial end portion 90 b of thevessel 90. The transversely-extending portion 120 d is connected to thehorizontally-extending portion 120 f at a location between the elbowconnections 120 g and 120 h. In an exemplary embodiment, as shown inFIGS. 9-12, the horizontally-extending portion 120 f includes aT-connection 120 i, to which at least the transversely-extending portion120 d and the elbow connection 120 g are connected. In another exemplaryembodiment, the horizontally-extending portion 120 f includes a crossconnection (not shown), to which at least the transversely-extendingportion 120 d and the elbow connection 120 g are connected.

As shown in FIGS. 9, 10, and 12, the elbow connections 120 g and 120 hextend angularly, from the horizontally-extending portion 120 f andtowards the vessel 90. As shown most clearly in FIG. 10, this angularextension defines an angle 122, relative to a horizontal plane 123defined by the skid 88 and on which the vessel mounting brackets 92 a,92 b, and 92 c are mounted. In an exemplary embodiment, the angle 122ranges from greater than 0 degrees to less than 90 degrees. In anexemplary embodiment, the angle 122 ranges from about 10 degrees toabout 80 degrees. In an exemplary embodiment, the angle 122 ranges fromabout 15 degrees to about 75 degrees. In an exemplary embodiment, theangle 122 ranges from about 20, 30, 40, or 50 degrees, and to about 70degrees. In an exemplary embodiment, the angle 122 is about 60 degrees.In an exemplary embodiment, the angle 122 is about 45 degrees.

In an exemplary embodiment, the horizontally-extending portion 120 f maybe located closer to the side portion 88 d than to the side portion 88c, the elbow connections 120 h and 120 i may extend angularly towardsthe vessel 90, and the angle 122 may be a symmetric equivalent, aboutthe generally centered vent pipe 106, of the exemplary embodiment of theangle 122 shown in FIG. 10.

A working platform 124 is connected to the vessel 90 and positionedabove the side portion 88 d of the skid 88. The working platform 124 isproximate the outlet pipe 98 so that any personnel installing,disassembling, inspecting, or operating the apparatus 76, or conductingother activities related to the apparatus 76, can access at least theconcentric reducer 102, the flame arrestor 104, and the vent pipe 106. Astairway assembly 126 extends from the side portion 88 d of the skid 88,and to the working platform 124, thereby providing access to the workingplatform 124.

In several exemplary embodiments, the respective sizes of the apparatus76 and its components may be scaled accordingly. In an exemplaryembodiment, the length 88 a and width 88 b of the skid 12 may be about189 inches and 92 inches, respectively. In an exemplary embodiment, theheight of the upper end portion of the igniter 108, from the horizontalsurface on which the skid 88 rests, may be about 336 inches.

In an exemplary embodiment, as illustrated in FIGS. 13 and 14 withcontinuing reference to FIGS. 8-12, the vessel 90 defines a cylindricalinside surface 90 e, as well as an internal region 128 with which theinlet pipe 120 is in fluid communication. More particularly, the elbowconnections 120 g and 120 h of the inlet pipe 120 are in fluidcommunication with the internal region 128. The outlet pipe 98 is influid communication with the internal region 128. The drain pipe 110 isin fluid communication with the internal region 128 at two locations.More particularly, the drain pipe 110 includes a vertically-extendingduct 110 c that is connected to the underside of the vessel 90 at theaxial end portion 90 a thereof. The vertically-extending duct 110 c isin fluid communication with the internal region 128. Additionally, thedrain pipe 110 includes an elbow connection 110 d at the end of thedrain pipe 110 opposite the inlet 110 a. The elbow connection 110 d isconnected to the underside of the vessel 90, and is in fluidcommunication with the internal region 128. A plate 130 a is connectedto the inside surface 90 e, and extends across the intersection betweenthe vertically-extending duct 110 c and the vessel 90. Likewise, a plate130 b is connected to the inside surface 90 e, and extends across theintersection between the elbow connection 110 d and the vessel 90. Theplates 130 a and 130 b extend upwards from the inside surface 90 e andwithin the internal region 128. Under conditions to be described below,the plates 130 a and 130 b are adapted to operate as vortex breakers.

As shown in FIG. 13, the liquid-level switch 118 is exposed to theinternal region 128 via the intersection between the sensor pipe 116 andthe vessel 90. In an exemplary embodiment, the liquid-level switch 118extends out from the sensor pipe 116 and into the internal region 128. Aheight H is defined between the nominal center of the liquid-levelswitch 118 and the tangential bottom of the inside surface 90 e.

In an exemplary embodiment, as illustrated in FIG. 15 with continuingreference to FIGS. 8-14, the apparatus 76 includes guide wires 132 a,132 b, 132 c, and 132 d, which extend to the igniter 108 from respectiveones of the four corners defined by the skid 88. In an exemplaryembodiment, the guide wires 132 a, 132 b, 132 c, and 132 d are connectedto the igniter 108 at the connection thereof with the vent pipe 106, asshown in FIG. 15. In an exemplary embodiment, the guide wires 132 a, 132b, 132 c, and 132 d are connected to the igniter 108 at a location otherthan at the connection between the igniter 108 and the vent pipe 106. Inan exemplary embodiment, the apparatus 76 includes one or more otherguide wires, in addition to the guide wires 132 a, 132 b, 132 c, and 132d. In an exemplary embodiment, at least one of the guide wires 132 a,132 b, 132 c, and 132 d is omitted from the apparatus 76; in such anexemplary embodiment, the remaining ones of the guide wires 132 a, 132b, 132 c, and 132 d may be connected to the skid 88 at respectivelocations other than the corners of the skid 88. In an exemplaryembodiment, one or more of the guide wires 132 a, 132 b, 132 c, and 132d may be connected to the skid 88 at respective locations other than thecorners of the skid 88.

In operation, in an exemplary embodiment, with continuing reference toFIGS. 8-15, a multiphase flow travels from the one or more separators82, through the one or more fluid lines 86, and into the inlet pipe 120of the apparatus 76 via the fluid inlet 84. In several exemplaryembodiments, the multiphase flow is, or includes, vent gas from the oneor more separators 82.

The multiphase flow travels through the horizontally-extending portion120 a, the elbow connection 120 c, the vertically-extending portion 120b, the elbow connection 120 e, and the transversely-extending portion120 d of the inlet pipe 120. Upon exiting the transversely-extendingportion 120 d, the multiphase flow splits into two different flow paths.More particularly, one portion of the multiphase flow travels throughthe elbow connection 120 g and into the internal region 128, asindicated by an arrow 134 in FIG. 13; the other portion of themultiphase flow travels through the elbow connection 120 h and into theinternal region 128, as indicated by an arrow 136 in FIGS. 13 and 14.Due to the angle 122, the respective portions of the multiphase flowinto the internal region 128, as indicated by the arrows 134 and 136, ina generally angular direction that corresponds to the angle 122. Themultiphase flow traveling through the one or more fluid lines 86includes solid, liquid, and gas materials. Within the internal region128, the solid and liquid materials separate from the gas materials inthe multiphase flow; the gas materials rise or flow upwards through theoutlet pipe 98, the concentric reducer 102, the flame arrestor 104, andthe vent pipe 106, and into the igniter 108. This upward flow of the gasmaterials is indicated by an arrow 138 in FIGS. 13 and 14. In severalexemplary embodiments, the remaining solid and liquid materials (whichhave been separated from the gas materials) collect within, and arecontained by, the drain pipe 110 and the vessel 90; the valve 110 b isclosed so that the remaining solid and liquid materials may be containedwithin the drain pipe 110 and the vessel 90.

In several exemplary embodiments, during operation, the remaining solidand liquid materials (which have been separated from the gas materials)collect within the vessel 90 and then may be drained out via the drainpipe 110. More particularly, the remaining solid and liquid materialsflow through the duct 110 c and the elbow connection 110 d, then throughthe remainder of the drain pipe 110, exiting the drain pipe 110 via thefluid outlet 110 a, as indicated by an arrow 140 in FIG. 13. Duringoperation, in several exemplary embodiments, the valve 110 b is open orpartially open to permit the remaining solid and liquid materials toexit the drain pipe 110 via the fluid outlet 110 a. In several exemplaryembodiments, the remaining solid and liquid materials flow through oneor more additional fluid lines that are in fluid communication with thefluid outlet 110 a, and to an external tank or fluid reservoir forcollection and storage therewithin.

As noted above, the gas materials rise or flow upwards through theoutlet pipe 98, the concentric reducer 102, the flame arrestor 104, andthe vent pipe 106, and into the igniter 108. The igniter 108 operates toburn off the gas materials that flow therein. As noted above, in severalexemplary embodiments, the combination of at least the vent pipe 106 andthe igniter 108 connected thereto constitutes a flare stack having anintegrated igniter at the upper end portion thereof; the flare stackoperates to burn off the gas materials that flow therein. In severalexemplary embodiments, the igniter 108 includes one or morethermocouples and/or other sensors, which may be in communication withthe igniter control box 112 and/or other controller(s) to monitortemperatures and/or other operating condition(s) of the igniter 108during the operation of the apparatus 76; in some exemplary embodiments,the igniter control box 112 may activate an alarm and/or take otheraction(s) in response to this monitoring.

The flame arrestor 104 allows the gas materials to flow therethrough,but arrests or stops a flame from propagating therethrough in order toprevent a larger fire or explosion. In several exemplary embodiments,the flame arrestor 104 stops any flame, within the vent pipe 106 or theigniter 108, from propagating through the flame arrestor 104 and intothe vessel 90. The flame arrestor 104 prevents post-separation flameflashback. In several exemplary embodiments, the flame arrestor 104includes one or more thermocouples and/or other sensors, which may be incommunication with one or more controllers to monitor the temperatureand/or other operating condition(s) of the flame arrestor 104 during theoperation of the apparatus 76; in some exemplary embodiments, the one ormore controllers may activate an alarm and/or take other action(s) inresponse to the monitoring; in several exemplary embodiments, the one ormore controllers include the igniter control box 112. In severalexemplary embodiments, the igniter 108 provides increased safety due toan increased elevation of flare, and the flame arrestor 104 providesintegrated flare flashback prevention.

During operation, in several exemplary embodiments, to separate thesolid and liquid materials from the gas materials in the multiphaseflow, the vessel 90 is sized so that the lighter gas materials arepermitted to rise or flow upwards towards the outlet pipe 98, and sothat the heavier solid and liquid materials fall to the bottom of thevessel 90 for containment therein and/or drainage therefrom.

During operation, in several exemplary embodiments, the splitting of themultiphase flow into at least two different flow paths within thehorizontally-extending portion 120 f of the inlet pipe 120 reduces theflow velocities of the multiphase flow as it enters the internal region128 (as indicated by the arrows 134 and 136), thereby improving theseparation of the solid and liquid materials from the gas materialswithin the internal region 128. During operation, in several exemplaryembodiments, the respective angular extensions of the elbow connections120 g and 120 h further facilitate the dissipation or reduction of theflow velocities of the multiphase flow as it enters the internal region128 (as indicated by the arrows 134 and 136), thereby further improvingthe separation of the solid and liquid materials from the gas materialswithin the internal region 128.

During operation, in several exemplary embodiments, the plates 130 a and130 b operate as vortex breakers, preventing gas materials fromentraining in the solid and liquid materials being drained from thevessel 90, or otherwise entering the drain pipe 110, via the duct 110 cand the elbow connection 110 d.

During operation, in several exemplary embodiments, if the level of theliquid materials within the vessel 90 reaches a predetermined level, theliquid-level switch 118 detects that the liquid level has reached thepredetermined level. In an exemplary embodiment, in response to thisdetection, the liquid-level switch 118 causes one or more alarms to beactivated and/or causes other action(s) to be taken. In an exemplaryembodiment, the liquid-level switch 118 is in communication with acontroller, and sends one or more signals to the controller in responseto detecting that the liquid level has reached the predetermined levelwithin the vessel 90; the controller may activate an alarm and/or takeother action(s) in response to receiving the one or more signals fromthe liquid-level switch 118. In an exemplary embodiment, the controllerin communication with the liquid-level switch 118 is, or includes, theigniter control box 112. In an exemplary embodiment, the predeterminedlevel that the liquid-level switch 118 is adapted to detect is generallyequal to about the height H of the liquid-level switch 118 within theinternal region 128. In an exemplary embodiment, the height H of theliquid-level switch 118 within the internal region 128 is about 10inches. In an exemplary embodiment, the predetermined level that theliquid-level switch 118 is adapted to detect is generally equal to aboutthe height H of the liquid-level switch 118 within the internal region128, and the height H is about 10 inches. In an exemplary embodiment,the predetermined level that the liquid-level switch 118 is adapted todetect is generally equal to about the height H of the liquid-levelswitch 118 within the internal region 128, the diameter of the vessel 90is about 48 inches, the axial length of the vessel 90 is about 144inches, and the height H of the liquid-level switch 118 within theinternal region 128 is about 10 inches; in several exemplaryexperimental embodiments, it has been determined that the foregoingcombination of dimensions ensures that the predetermined level(generally equal to the height H) is low enough to provide enoughresponse time if the vessel 90 begins to experience overflow, but highenough to allow the apparatus 76 to operate freely, ensuring that avolume, within the internal region 28 and above the liquid-level switch118, is sufficient for the separation of the solid and liquid materialsfrom the gas materials in the multiphase flow. In several exemplaryembodiments, the liquid-level switch 118 may operate in accordance withthe foregoing when the valve 110 b is closed, partially open, orcompletely open.

During the operation of the apparatus 76, in several exemplaryembodiments, the guide wires 132 a, 132 b, 132 c, and 132 d secure andstabilize the igniter 108. In several exemplary embodiments, the guidewires 132 a, 132 b, 132 c, and 132 d secure and stabilize the igniter108 during the installation of the apparatus 76 at the wellsite 78. Thestabilization provided by the guide wires 132 a, 132 b, 132 c, and 132 dis facilitated by the vessel 90 being centered on the skid 88, and bythe outlet pipe 98 being centered on the top of the vessel 90.

During operation, in several exemplary embodiments, due at least in partto the vessel 90, separation is achieved in a closed system, withpost-separation dynamics ensuring that only vent gas is discharged tothe vent pipe 106. More particularly, during operation, the cap flange90 d is connected to the access port 90 c and the vessel 90 is a closedvessel, that is, closed to the atmosphere, with no part of the vesselbeing directly open to the atmosphere. Thus, separation is achieved in aclosed system, with post-separation dynamics ensuring that only vent gasis discharged to the vent pipe 106.

In several exemplary embodiments, the one or more fluid lines 86 is avent gas line, and the apparatus 76 functions both as a vent gasseparator and a secondary containment flare system. The apparatus 76effectively separates and contains solid and liquid carryover in thevent gas flowing through the fluid lines 86 and into the apparatus 76,while burning off the gas materials. In several exemplary embodiments,the apparatus 76 ensures the collection and storage of solid and liquidmaterials entrained in the vent gas. In several exemplary embodiments,the apparatus 76 is an integrated separator and secondary containmentflare apparatus. In several exemplary embodiments, the apparatus 76 isan integrated vent gas separator and secondary containment flareapparatus. In several exemplary embodiments, the apparatus 76 is anintegrated vent gas separator and flare stack.

In several exemplary embodiments, the above-described integration andvertical stack-up of the different components of the apparatus 76reduces the footprint of the apparatus 76 to the footprint of the skid88, thereby providing a compact structure. The apparatus 76 occupies asurface area at the wellsite 78 that is generally equal to the surfacearea that the skid 88 occupies at the wellsite 78. Further, theabove-described integration and vertical stack-up of the differentcomponents of the apparatus 76 facilitates the installation of theapparatus 76. Still further, the above-described integration andvertical stack-up of the different components of the apparatus 76facilitates the above-described operation of the apparatus 76 in that,for example, the heavier solid and liquid materials fall to the bottomof the vessel 90 for collection therewithin, and the lighter gasmaterials rise up out of the vessel 90, through the flame arrestor 104,through the vent pipe 106, and into the igniter 108.

In several exemplary embodiments, the configuration of the apparatus 76described above and illustrated in FIGS. 9-12 and 15 may be referred toas an installation configuration of the apparatus 76. In an exemplaryembodiment, the apparatus 76 has an installation configuration in whicheither the apparatus 76 is in fluid communication with the one or morefluid lines 86 (or another fluid line) and is able to operate inaccordance with the foregoing, or the apparatus 76 is able to be placedin fluid communication with the one or more fluid lines 86 (or anotherfluid line) and, when so placed, is able to operate in accordance withthe foregoing. In an exemplary embodiment, the apparatus has aninstallation configuration in which at least the flame arrestor 104extends vertically and is connected to the vessel 90, the vent pipe 106extends vertically and is connected to the flame arrestor 104 so thatthe flame arrestor 104 is vertically positioned between the vessel 90and the vent pipe 106, and the igniter 108 extends vertically and isconnected to the vent pipe 106 so that the vent pipe 106 is verticallypositioned between the flame arrestor 104 and the igniter 108.

In an exemplary embodiment, as illustrated in FIGS. 16-18 withcontinuing reference to FIGS. 8-15, the apparatus 76 has atransportation configuration in which the flame arrestor 104, the ventpipe 106, and the igniter 108 do not extend vertically and are notvertically stacked on top of each other. Instead, in the transportationconfiguration: the flame arrestor 104 extends horizontally and ismounted on the side portion 88 c of the skid 88 by being connected tothe flame arrestor mounting brackets 96 a and 96 b on the side portion88 c of the skid 88; the vent pipe 106 extends horizontally over theside portion 88 c and is connected to the vent pipe mounting brackets114 a and 114 b; the igniter 108 extends horizontally and is mounted onthe side portion 88 c of the skid 88 by being connected to the ignitermounting brackets 94 a and 94 b on the side portion 88 c of the skid 88;and the guide wires 132 a, 132 b, 132 c, and 132 d do not extend to theupper end portion of the igniter 108 from respective ones of the fourcorners defined by the skid 88. The transportation configuration of theapparatus 76 enables the apparatus 76 to be easily transported on atruck or other vehicle to the wellsite 78. The transportationconfiguration of the apparatus 76 reduces the volumetric envelope of theapparatus 76 to improve its transportability. In the transportationconfiguration of the apparatus 76, the flame arrestor 104, the vent pipe106, and the igniter 108 can all be accessed at the side portion 88 c ofthe skid 88. Therefore, only the side portion 88 c of the skid 88 needsto be accessible to installation personnel and installation equipmentsuch as, for example, forklifts or other devices. In an exemplaryembodiment, in the transportation configuration of the apparatus 76,installation personnel, either manually or using a forklift or otherdevice, can access any one of the flame arrestor 104, the vent pipe 106,and the igniter 108 by moving in a common direction towards the sideportion 88 c, as indicated by an arrow 142 in FIGS. 16 and 17.

In an exemplary embodiment, as illustrated in FIG. 19 with continuingreference to FIGS. 1-18, a method of installing the apparatus 76 isgenerally referred to by the reference numeral 144. The method 144includes at step 144 a accessing the flame arrestor 104 at the sideportion 88 c of the skid 88 and disconnecting the flame arrestor 104from the flame arrestor mounting brackets 96 a and 96 b. At step 144 b,the flame arrestor 104 is connected to the concentric reducer 102 sothat the flame arrestor 104 extends vertically. At step 144 c, thehorizontally-extending vent pipe 106 is accessed at the side portion 88c and disconnected from the vent pipe mounting brackets 114 a and 114 b.At step 144 d, the vent pipe 106 is connected to the flame arrestor 104so that the vent pipe 106 extends vertically. At step 144 e, the igniter108 is accessed at the side portion 88 c and disconnected from theigniter mounting brackets 94 a and 94 b. At step 144 f, the igniter 108is connected to the vent pipe 106 so that the igniter 108 extendsvertically. At step 144 g, the guide wires 132 a, 132 b, 132 c, and 132d are connected to the upper end portion of the igniter 108 andrespective ones of the four corners of the skid 88. In several exemplaryembodiments, the steps 144 a, 144 b, 144 c, 144 d, 144 e, 144 f, and 144g may be performed in different orders, simultaneously, sequentially, orany combination thereof. Regardless of the order of performance, theexecution of the method 144 changes the configuration of the apparatus76 from its transportation configuration shown in FIGS. 16-18 to itsinstallation configuration shown in FIGS. 9-12 and 15.

In the foregoing description of certain embodiments, specificterminology has been resorted to for the sake of clarity. However, thedisclosure is not intended to be limited to the specific terms soselected, and it is to be understood that each specific term includesother technical equivalents which operate in a similar manner toaccomplish a similar technical purpose. Terms such as “left” and right”,“front” and “rear”, “above” and “below” and the like are used as wordsof convenience to provide reference points and are not to be construedas limiting terms.

In this specification, the word “comprising” is to be understood in its“open” sense, that is, in the sense of “including”, and thus not limitedto its “closed” sense, that is the sense of “consisting only of”. Acorresponding meaning is to be attributed to the corresponding words“comprise”, “comprised” and “comprises” where they appear.

In addition, the foregoing describes only some embodiments of theinvention(s), and alterations, modifications, additions and/or changescan be made thereto without departing from the scope and spirit of thedisclosed embodiments, the embodiments being illustrative and notrestrictive.

Furthermore, invention(s) have described in connection with what arepresently considered to be the most practical and preferred embodiments,it is to be understood that the invention is not to be limited to thedisclosed embodiments, but on the contrary, is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the invention(s). Also, the various embodiments described abovemay be implemented in conjunction with other embodiments, e.g., aspectsof one embodiment may be combined with aspects of another embodiment torealize yet other embodiments. Further, each independent feature orcomponent of any given assembly may constitute an additional embodiment.

What is claimed is:
 1. An apparatus, comprising: a separator vessel adapted to separate solid and liquid materials from gas materials; a flame arrestor in fluid communication with the separator vessel and through which the gas materials are adapted to flow; and a flare stack adapted to burn off the gas materials, wherein the flare stack is positioned so that the flame arrestor is vertically positioned between the separator vessel and the flare stack, and wherein the flare stack comprises: a vent pipe in fluid communication with the flame arrestor and positioned so that the flame arrestor is vertically positioned between the separator vessel and vent pipe; and an igniter in fluid communication with the vent pipe, wherein the igniter is positioned so that the vent pipe is vertically positioned between the flame arrestor and the igniter.
 2. The apparatus of claim 1, further comprising a skid on which the separator vessel, the flame arrestor, and the flare stack are mounted; wherein the flame arrestor is positioned so that the separator vessel is vertically positioned between the skid and the flame arrestor.
 3. The apparatus of claim 2, further comprising one or more guide wires extending from the skid to the flare stack to secure and stabilize the igniter.
 4. The apparatus of claim 2, further comprising an outlet pipe generally centered on the top of the separator vessel and extending upward therefrom; wherein the flame arrestor is in fluid communication with the outlet pipe and is positioned so that the outlet pipe is vertically positioned between the separator vessel and the flame arrestor; and wherein the separator vessel is generally centered on the skid.
 5. The apparatus of claim 4, wherein the apparatus comprises one or more guide wires to secure and stabilize the igniter, each of the one or more guide wires extending to the flare stack from the skid; and wherein the centering of the outlet pipe on the top of the separator vessel, and the centering of the separator vessel on the skid, facilitates the securement and stabilization of the igniter by the one or more guide wires.
 6. The apparatus of claim 1, wherein the separator vessel defines an internal region and comprises an access port and a cap flange removably connected thereto; wherein the access port provides access to the internal region; and wherein, when the solid and liquid materials are separated from the gas materials, the cap flange is connected to the access port and the separator vessel is a closed vessel that is closed to the atmosphere.
 7. The apparatus of claim 1, wherein the separator defines an internal region in which the solid and liquid materials are adapted to be separated from the gas materials; wherein the apparatus further comprises an inlet pipe via which the solid, liquid, and gas materials are adapted to flow into the internal region; wherein the inlet pipe comprises a first connection that extends angularly towards the separator vessel and is connected thereto; wherein the angular extension of the first connection defines an angle from a horizontal plane; and wherein the angle from the horizontal plane ranges from greater than 0 degrees to less than 90 degrees.
 8. The apparatus of claim 7, wherein at least respective portions of the solid, liquid, and gas materials are adapted to flow into the internal region, via the first connection, in a generally angular direction that corresponds to the first angle; and wherein the first angle ranges from about 10 degrees to about 80 degrees.
 9. The apparatus of claim 1, wherein the separator defines an internal region in which the solid and liquid materials are adapted to be separated from the gas materials; wherein the apparatus further comprises an inlet pipe via which the solid, liquid, and gas materials are adapted to flow into the internal region; wherein the inlet pipe comprises a horizontally-extending portion that extends axially along the separator vessel, the horizontally-extending portion comprising first and second connections located at opposing ends, respectively, of the horizontally-extending portion; wherein the first and second connections are connected to the separator vessel; wherein the solid, liquid, and gas materials are adapted to flow into the internal region via the first and second connections.
 10. The apparatus of claim 9, wherein each of the first and second connections extends angularly towards the separator vessel; wherein each of the angular extensions of the first and second connections defines an angle from a horizontal plane; and wherein the angle from the horizontal plane ranges from greater than 0 degrees to less than 90 degrees.
 11. A system at a wellsite, the system comprising: one or more separators adapted to be in fluid communication with a wellbore at the wellsite; one or more vent gas lines in fluid communication with the one or more separators; and an integrated vent gas separator and flare stack, comprising: a skid; a vessel mounted on the skid, in fluid communication with the one or more vent gas lines, and adapted to separate solid and liquid materials from gas materials; a flame arrestor in fluid communication with the vessel and positioned so that the vessel is vertically positioned between the skid and the flame arrestor; and a flare stack in fluid communication with the flame arrestor and adapted to burn off the gas materials, wherein the flare stack is positioned so that the flame arrestor is vertically positioned between the vessel and the flare stack.
 12. The system of claim 11, wherein the flare stack comprises a vent pipe and an igniter connected thereto.
 13. The system of claim 12, further comprising one or more guide wires extending from the skid to the flare stack; wherein the one or more guide wires secure and stabilize the igniter.
 14. The system of claim 11, wherein the vessel defines an internal region and comprises an access port and a cap flange removably connected thereto; wherein the access port provides access to the internal region; and wherein, when the solid and liquid materials are separated from the gas materials, the cap flange is connected to the access port and the vessel is a closed vessel that is closed to the atmosphere.
 15. The system of claim 11, wherein the one or more separators comprise at least one of a mud-gas separator and a shale-gas separator.
 16. A kit which, when assembled, is adapted to process a multiphase flow at a wellsite, the multiphase flow comprising solid, liquid, and gas materials, the kit comprising: a skid; a vessel mounted on the skid and into which the multiphase flow is adapted to flow to separate the solid and liquid materials from the gas materials, wherein the mounting of the vessel on the skid defines opposing first and second side portions of the skid, and wherein the vessel is positioned between the opposing first and second side portions of the skid; an inlet pipe connected to the vessel and via which the multiphase is adapted to flow into the vessel, wherein at least a portion of the inlet pipe extends above the first side portion; a flame arrestor; a vent pipe; and an igniter; wherein the kit has: a first configuration in which: each of the flame arrestor, the vent pipe, and the igniter either is mounted on the second side portion of the skid or extends over the second side portion of the skid; and each of the vent pipe and the igniter extends horizontally; and a second configuration in which: the flame arrestor extends vertically and is positioned so that the vessel is vertically positioned between the skid and the flame arrestor; the gas materials are adapted to flow through the flame arrestor; the vent pipe extends vertically and is positioned so that the flame arrestor is vertically positioned between the vessel and the vent pipe; the gas materials are adapted to flow through the vent pipe; the igniter extends vertically and is positioned so that the vent pipe is vertically positioned between the flame arrestor and the igniter; and the igniter is adapted to burn off the gas materials.
 17. The kit of claim 16 wherein, when the kit is in the first configuration: one of the vent pipe and the igniter is mounted on the second side portion of the skid; the other of the vent pipe and the igniter extends above the second side portion of the skid; and the flame arrestor is mounted on the second side portion of the skid.
 18. The kit of claim 16 wherein the vessel defines an internal region and comprises an access port and a cap flange removably connected thereto; wherein the access port provides access to the internal region; and wherein, when the solid and liquid materials are separated from the gas materials, the cap flange is connected to the access port and the vessel is a closed vessel that is closed to the atmosphere.
 19. A method, comprising: providing a skid and a separator vessel mounted on the skid, wherein the mounting of the separator vessel on the skid defines opposing first and second side portions of the skid, wherein the separator vessel is positioned between the opposing first and second side portions of the skid, and wherein each of a flame arrestor, a horizontally-extending vent pipe, and a horizontally-extending igniter either is mounted on the second side portion of the skid or extends over the second side portion of the skid; accessing the flame arrestor at the second side portion of the skid; connecting the flame arrestor to the separator vessel so that the flame arrestor extends vertically; accessing the horizontally-extending vent pipe at the second side portion of the skid; connecting the vent pipe to the flame arrestor so that the vent pipe extends vertically; accessing the horizontally-extending igniter at the second side portion of the skid; and connecting the igniter to the vent pipe so that the igniter extends vertically.
 20. The method of claim 19, further comprising connecting one or more guide wires between the igniter and the skid to secure and stabilize the igniter.
 21. The method of claim 19, wherein an inlet pipe is connected to the separator vessel and at least a portion of the inlet pipe extends over the first side portion of the skid; and wherein the method further comprises: connecting one or more fluid lines to the inlet pipe; conveying a multiphase flow into the separator vessel via the one or more fluid lines and the inlet pipe, the multiphase flow comprising solid, liquid, and gas materials; separating, using the separator vessel, the solid and liquid materials from the gas materials; conveying the gas materials upwardly into the flame arrestor; and conveying the gas materials upwardly from the flame arrestor and into the igniter.
 22. The method of claim 21, wherein the one or more fluid lines comprise at least one vent gas line that is in fluid communication with one of a mud-gas separator and a shale-gas separator.
 23. The method of claim 19, wherein the separator vessel defines an internal region and comprises an access port and a cap flange removably connected thereto, and wherein the access port provides access to the internal region. 